Dye Sublimation Fabric Separated Elements

ABSTRACT

A laminate that possesses dye sublimation properties, particularly for use as tagless labels and embellishments for garments, apparel, fabric items and so forth such as sportswear fabrics, clothing and accessories is provided. The laminate includes a dye sublimation ink layer that overlies a substrate in which the dye sublimation ink interacts with the substrate&#39;s chemical make-up.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the benefit of U.S. ProvisionalApplication No. 61/900,541 filed Nov. 6, 2013 which is incorporatedherein by reference in its entirety.

FIELD OF THE DISCLOSURE

The present subject matter relates to tagless labels and laminates thathave dye sublimation images and fabric separated characteristics,particularly for use as tagless labels and embellishments for garments,apparel, fabric items and so forth such as sportswear fabrics, clothingand accessories. The present subject matter is especially suitable forlabels that capture color strengths of digitally printed dye sublimationimages and enjoy the look and application methodology of heat transfertagless labels.

DESCRIPTION OF RELATED ART

Tagless labels are applied directly to the item to be labeled orembellished though a process that avoids attachment methods such asstitching or tacking and instead applies the label to the fabric orother substrate from a roll or cut single transfer in the presence ofheat and pressure. Such tagless labels can be seen by the user withouthaving the user experience the additional bulk typically associated witha separate tag that is affixed to the surface of the substrate that isbeing labeled or embellished while remaining as a separate piece.Instead, a tagless label is printed, hot-melt adhered or otherwiseapplied directly to the substrate such as a garment to eliminate orsubstantially reduce the feel of a separate tag that sewn or otherwiseattached to the substrate.

The tagless labels can include indicia and can be in the form ofdecoration, labels, patches, identification placards, embellishments andthe like that are widely used for a variety of different applicationsincluding product identification, product features, materials, sizes,styles, and so forth. Some can take the form of or include logos,trademarks, keyboard symbols, whether numeric, alphabetic oralphanumeric or other symbols, sports designs, logos and names, clothingdesign details, accents and backgrounds, artwork and the like.Typically, these indicia are included on assemblies in the nature ofheat transfer labels suitable for application on “soft goods” items suchas fabrics, clothing and accessories, including specific products suchas upper body wear, lower body wear, headwear, footwear, outerwear,underwear, garments, sportswear fabrics, other sheet goods, banners,flags, athletic or sport clothing and uniforms, government uniforms,organization uniforms, and combinations thereof.

Dye sublimation printing of textiles is discussed, for example, in U.S.Patent Application Publication No. 2009/075075 in which printed imagessimulate stitching providing a faux embroidery textile, using digitalimages to control dye sublimation printing in creating this effect. U.S.Patent Application Publication No. 2009/025123 digitally prints appliquéemblems by applying digitally printed appliqué indicia, as analternative to direct embroidery

U.S. Pat. No. 7,081,324 concerns dye sublimation thermal transfer sheetsused for applying to a receptor fabric, while providing a medium bywhich heat activated sublimation dyes can penetrate and adhere to asurface not inherently capable of supporting dye sublimation inks, suchas cotton. U.S. Patent Application Publication No. 2005/199152 describesusing sublimation or similar heat activated dyes which are activated andapplied to a substrate, printing both a reactive ink and a heatactivated dye on a substrate. Each of the publications identified hereinis incorporated by reference hereinto, especially for their informationregarding dye sublimation image formation and printing and for specificsof chemicals and materials suitable for use in dye sublimation digitalprinting.

SUMMARY

There are several aspects of the present subject matter which may beembodied separately or together in the devices and systems described andclaimed below. These aspects may be employed alone or in combinationwith other aspects of the subject matter described herein, and thedescription of these aspects together is not intended to preclude theuse of these aspects separately or the claiming of such aspectsseparately or in different combinations as may be set forth in theclaims appended hereto.

In one aspect of this disclosure, a digitally printed, dye sublimationink laminate is provided which includes a dye sublimation ink layeroverlying a polyester or base substrate layer. The dye from the inklayer sublimates into a material layer such as a polyester interactingwith the molecules of the polyester layer. An adhesive layer is adheredto the back face of the substrate or material layer. An optional layermay be releasably secured to the surface of the adhesive layer that isnot adhered to the material layer.

In another aspect of this disclosure, a digitally printed, dyesublimated printed laminate is provided in which the laminate includes asublimation ink layer on the front face of a substrate layer, anadhesive layer on the back face of the substrate layer, and a releaselayer releasably secured to the adhesive layer. A carrier overlies thesublimation ink layer forming a multi-layered lamination. In use, therelease layer is separated from the adhesive layer of the multi-layeredlamination, and the resulting separated elements lamination is affixedto an item such as a consumer good, particularly a garment of clothing.The carrier is separated from the image layer of the fabric separatedelements lamination to provide the label with a dye sublimationdigitally printed label.

In an additional aspect, the disclosure relates to a method of providinga digitally printed, dye sublimation ink laminate which includes anadhesive layer having a first surface and a second surface, an optionalrelease layer that is releasably secured to the first surface of theadhesive layer, a substrate overlying the second surface of the adhesivelayer, a digitally printed, dye sublimation ink layer having one surfaceoverlying the substrate, a pressure sensitive adhesive film carrieroverlying the other surface of the printed layer forming a multi-layeredlamination. The sublimation ink of the dye sublimation ink layer mayform an image and/or indicia. The method further includes separating therelease layer from the adhesive of the multi-layered lamination andforming a fabric separated elements lamination, then positioning thefabric separated elements lamination over a soft goods item, e.g.garment, apparel, and applying a heat and pressure regimen onto thepressure sensitive adhesive carrier, thereby affixing the lamination tothe soft goods item. The carrier is then removed from the digitallyprinted, dye sublimation layer after the lamination is affixed toprovide a digitally printed, dye sublimation label on the soft goodsitem. Optionally, a second heat and pressure regimen is applied onto thedye sublimation ink printed layer subsequent to removal of the carrier.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow chart illustration of the components of the dyesublimated digitally printed label and method of manufacture and methodof use; and

FIG. 2 is a plan view of a dye sublimated ink digitally printed labelaccording to the present disclosure;

DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

As required, detailed embodiments of the present invention are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely exemplary of the invention, which may be embodied in variousforms. Therefore, specific details disclosed herein are not to beinterpreted as limiting, but merely as a basis for the claims and as arepresentative basis for teaching one skilled in the art to variouslyemploy the present invention in virtually any appropriate manner.

FIG. 1 provides a flow chart for an embodiment of the product and methodof its production and use. First in step 100, a laminate (shown in FIG.2) is provided in which the laminate 40 has an adhesive layer 42 with afirst surface 50 and a second surface 51. A substrate 43 having a top 54and bottom 53 face is also provided such that the bottom face 53 of thesubstrate 43 overlies the second surface 51 of the adhesive layer 42.The layers are generally substantially juxtaposed on one another but itshould also be considered within the scope of this invention that thelayers may be slightly splayed out of alignment or extend beyond an edgeor side of one another.

In one embodiment, an optional release layer 41 may be provided suchthat the release layer is adhered to the first surface 50 of theadhesive layer 42. A dye sublimation ink layer 44 is provided over thetop face 54 of the substrate 43, and a carrier layer 45 is provided overthe ink layer 44 forming a multi-layered lamination. The sublimation inkof the dye sublimation ink layer 44 may be digitally printed as an imageand/or indicia, or may be a solid layer provided over the substrate.Next, in step 110, the laminate is bonded to an article which can be asoft consumer good such as an article of clothing. Bonding includes theutilization of both heat and pressure. Lastly, in step 120, the carrierlayer 45 is removed from the laminate 40. If a release layer 41 isutilized, it is removed from the laminate prior to bonding the laminateto the article.

In one embodiment, the laminate of the present invention is made readyfor application as a tagless label to a garment, fabric, or other itemby removal of the release layer, thereby exposing the adhesive layer. Itis also contemplated that the laminate can be cut into different shapesand sizes for application purposes. For example, the laminate may be cutinto a particular numeral or letter for a jersey or other garment in oneembodiment. Alternatively, the laminate may take any shape such as atrademark or any other geometric configuration. It is important to notethat the release layer is optional and is not required to be utilized.The laminate is bonded to the garment or other soft good typically withthe use of a bonding machine that applies heat and pressure for aselected time period in step 110 of the method illustrated in FIG. 1. Anexample of a suitable bonding machine for use with the present method isAvery Dennison AD-718 which is a bonding machine that applies heat fromthe top surface only such that the heat penetrates down through thelayers. In some applications, a second pass through the bonding machine,after the carrier layer is removed occurs.

FIG. 2 illustrates the construction of a digitally printed, sublimationdye laminate according to the present invention. FIG. 2 shows the labelgenerally depicted by reference numeral 40 having an adhesive layer 42disposed between a first surface 50 and a second surface 51. An optionalrelease layer 41 may be adhered to the first surface 50 of the adhesivelayer 42. A substrate layer 43 having a top 54 and bottom face 53 isprovided over the second surface 51 of the adhesive layer 42. A dyesublimation ink layer 44 is provided over the substrate layer 43, and anoptional carrier layer 45 overlies the ink layer. The dye sublimationink layer in one embodiment is digitally printed onto the substratelayer. The sublimation ink may form an image, character and/or indicia.

The digitally printed, dye sublimation ink layer sublimates into thesubstrate layer and interacts with the molecules of the substrate layer.By the ink of the image and/or indicia interacting with the substratelayer, the laminate of the present invention has increased durabilitywhich is an improvement over that which is already in the marketplace.The image or indicia made out of sublimation dye is printed in reverseon the substrate to allow for the image and/or indicia to be easily readwhen transferred. In one embodiment the substrate layer 43 is a coatedpaper layer. The substrate 43 may also be a material layer such as apolyester, a polyester blend, or poly-spandex. The substrate may also beeither a film, or any other dye sub ink receptive ink fabric/polymer.

In one embodiment, the substrate layer may be a reflective fabric.

The adhesive layer 42 is generally a hot melt adhesive layer, such as apolyester type of hot melt adhesive. Various hot melt adhesive are knownin the art. This adhesive layer 42 is to be suitable for tagless labeldelivery and adherence, typically being thinner than the thickness ofthe dye sublimation fabric layer, generally on the order of one-thirdthe thickness. Illustrative of adhesive layer thicknesses in this regardare within a range between about 1 and about 7 mills (about 25 and about178 microns), or between about 2 and about 5 mills (about 50 and about127 microns), or between about 2 and about 4 mills (about 50 and about100 microns).

With further reference to the adhesive layer 42 described in connectionwith the present embodiments, the adhesive 42 has a modulus suitable towithstand high temperature wash tests such as those required by someapparel manufacturers. The adhesive also has to have suitable adhesionto synthetic fibers during hot melt adhesion. Usually, the adhesive iscontinuously extruded or flood coated to a thickness as discussedherein. In many applications, the adhesive needs to melt and flow in thefabric texture at a temperature of between 250 and 350° F.(approximately 121 to 177° C.) when heated for 5 to 50 seconds. In someapplications, the bonding temperature is between about 285 and 330° F.(approximately 140 to 165° C.).

The present invention contemplates that in one embodiment the dyesublimation ink layer 44 may have a portion of said layer which does notexhibit sublimation dye properties such that the sublimation dye doesnot interact with the substrate.

In order to facilitate protection and delivery of the label, a supportportion such as a release layer can be provided which providesmechanical strength to the label assembly allowing handling such asbeing wound up in a roll for storage, stacking, and as a label feed formechanized operations. Basically, the support portion comprises both thesheet carrier and release layer. Typical carriers are cellulosic orpolymeric film. A typical release layer is a low melting temperature,thinly coated film on a sheet carrier that facilitates peeling of thetransfer portion from the sheet carrier when the heat transfer iscompleted. Another example of a release layer that could be utilized isa silicon coated paper release layer.

The carrier layer 45 may be a pressure sensitive adhesive film in oneembodiment. The combined thickness of the dye sublimation ink layer 44and carrier layer 45 may be between approximately 2.5 and 3.5 times thecombined thickness of the release layer and the adhesive layer. Thepresent invention also contemplates that in one embodiment the carrierlayer may be heat resistant.

In one embodiment of the present invention, a particular image, such asa number or letter, can be completely cut out of the laminate 40. Thecutting can be accomplished by a laser, mechanical die cut, or plottercutter and can be done prior to separation of the release layer and thecarrier from the multi-layered laminate construction.

It will be understood that the embodiments described above areillustrative of some of the applications of the principles of thepresent subject matter. Numerous modifications may be made by thoseskilled in the art without departing from the spirit and scope of theclaimed subject matter, including those combinations of features thatare individually disclosed or claimed herein. For these reasons, thescope hereof is not limited to the above description but is as set forthin the following claims, and it is understood that claims may bedirected to the features hereof, including as combinations of featuresthat are individually disclosed or claimed herein.

1. A laminate, comprising: an adhesive layer having a first surface anda second surface; a substrate layer having a top and bottom face whereinthe bottom face of the substrate layer overlies the second surface ofthe adhesive layer a dye sublimation ink layer that overlies the topface of the substrate layer; a carrier layer that overlies the dyesublimation ink layer; and wherein the dye sublimation interacts withthe substrate layer.
 2. The laminate of 1, wherein the substrate layeris a polyester.
 3. The laminate of claim 1, further comprising a releaselayer adhered to the first face of the adhesive layer.
 4. The laminateof 3, wherein the combined thickness of the dye sublimation ink layerand carrier layer are between approximately 2.5 and 3.5 times thecombined thickness of the release layer and the adhesive.
 5. Thelaminate of claim 1, wherein the carrier layer is a pressure sensitiveadhesive film
 6. The laminate of claim 1, wherein the carrier layer heatresistant.
 7. The laminate of claim 1, wherein the adhesive of claim 1is a hot melt adhesive.
 8. The laminate of 1, wherein the dyesublimation ink layer is digitally printed and includes an image and/orindicia.
 9. The laminate of claim 1, wherein the thickness of said dyesublimation ink layer is between about 7 and about 10 mils (about 178and about 254 microns), and the thickness of the adhesive layer isbetween about 2 and about 5 mils (about 50 and about 127 microns). 10.The laminate of claim 1, wherein the substrate layer is a fabric layer.11. A dye sublimation ink laminate, comprising: a hot melt adhesivelayer having a first surface and a second surface; a release layer thatis releasably secured to the first surface of the hot melt adhesivelayer; a polyester layer having a top and bottom face wherein the bottomface is adhered to the second surface of the hot melt adhesive layer; adigitally printed, dye sublimation ink layer having one surfaceoverlying the top face of the polyester layer wherein the ink layersublimates into the polyester layer; a pressure sensitive adhesive filmcarrier overlying the dye sublimation digitally printed, dye sublimationink layer forming a multi-layered assembly lamination; and wherein therelease layer separates from the hot melt adhesive of the multi-layeredlamination, and the pressure sensitive adhesive film carrier separatesfrom the digitally printed, dye sublimation layer of the multi-layeredlamination to provide the dye sublimation digitally printed laminate.12. The laminate of claim 11, wherein the multi-layered lamination isformed by cutting into a desired shape of the laminate prior toseparation of the release layer and the pressure sensitive adhesive filmcarrier from the multi-layered laminate.
 13. The laminate of claim 11,wherein the thickness of said dye sublimation digitally printed layer isbetween about 7 and about 10 mils (about 178 and about 254 microns), andthe thickness of said hot melt adhesive layer is between about 2 andabout 5 mils (about 50 and about 127 microns).
 14. A method of applyinga dye sublimated laminate to an article, comprising: providing alaminate having an adhesive layer having a first surface and a secondsurface, a material layer having a top and bottom face wherein thebottom face of the material layer overlies the second surface of theadhesive layer, and a dye sublimation ink layer that overlies the topface of the material layer; and bonding the laminate to an article usingheat and pressure wherein the dye sublimation ink layer sublimates intothe material layer.
 15. The method of claim 14, wherein the laminatefurther comprises a release layer adhered to the first surface of theadhesive layer.
 16. The method of claim 14, wherein the release layer isremoved prior to bonding the laminate to an article.
 17. The method ofclaim 14, wherein the laminate further comprises a carrier layer thatover the dye sublimation ink layer.